Elastic laminates with curved elastics and methods for manufacturing

ABSTRACT

Elasticated materials and articles comprising elasticated materials are disclosed. A method may comprise advancing first and second substrate materials and a stretched elastomeric strand in the machine direction. The method may further comprise advancing the first and the second substrate materials with the elastomeric strand positioned therebetween to a bonding apparatus. The bonding apparatus may comprise first and second elements forming a bonding nip. The method may further comprise oscillating the strand in a cross-machine direction and advancing the first and second substrate materials, and the strand, through the bonding nip and bonding the first and second substrate materials together with at least first and second bonds. The first and second bonds may be disposed on opposite sides of the strand and spaced apart a distance less than its un-tensioned diameter, and the first and second bonds may be located along an arcuate portion of the strand.

PRIORITY CLAIM

The present application claims priority to U.S. Provisional ApplicationNo. 62/579,546, entitled “Elastic Laminates With Curved Elastics AndMethods For Manufacturing” and filed on Oct. 31, 2017, and to U.S.Provisional Application No. 62/579,494, entitled “Elastic Laminates WithCurved Elastics And Methods For Manufacturing” and filed on Oct. 31,2017, the contents of which are hereby incorporated by reference in amanner consistent with the present application.

TECHNICAL FIELD

The present disclosure relates to elasticated materials, and morespecifically elasticated materials that have curved elastomeric strands.

BACKGROUND OF THE DISCLOSURE

Elasticated materials are used in many different applications, includingwithin various clothing garments and absorbent articles. Suchelasticated materials may be used as part of waistbands, leg cuffs,barrier cuffs, or in other components of clothing garments and absorbentarticles to provide beneficial fit characteristics, help prevent leakageof bodily exudates, or impart other benefits.

Many current clothing garments and absorbent articles includeelasticated materials which comprise elastomeric strands positionedbetween layers of material and affixed to the layers of material withadhesive. Some prior art elasticated materials have attempted to removethe adhesive in favor of affixing the elastomeric strands to the layersof material with the use of discrete individual bonds. These prior artmaterials position the bonds across the elastomeric strands a distanceless than the un-tensioned diameter of the elastomeric strands. Someexample prior art materials can be seen in U.S. Pat. No. 6,291,039 toCera France Compagnie d'Equipment Robotique Appliquee, titled “RufflingSlide and Method for Making Same”. This particular structuralconfiguration holds the elastomeric strands in place within theelasticated material between the bonds. These adhesive-less elasticatedmaterials have a cost advantage as they do not require adhesive to affixthe elastomeric strands within the elasticated material. Formingelasticated materials in this fashion with curved elastomeric strandshas been found to be problematic, as curving the elastomeric strandsduring manufacture of such elasticated materials can cause the bonds tobe formed through the elastomeric strands, thereby breaking or otherwisedamaging the elastomeric strands. Accordingly, elasticated materials andprocesses to form elasticated materials which do not include adhesiveand which include curved elastomeric strands and which do not sufferfrom strand breakage are desired.

SUMMARY OF THE DISCLOSURE

The present disclosure relates to elasticated materials, and morespecifically elasticated materials that have curved elastomeric strands.In general, the elasticated materials of the present disclosure areconstructed without adhesive and include elastomeric strands which forma generally arcuate or curved shape. Forming elasticated materialswithout the use of adhesive provides a great cost advantage in terms ofreduction in the adhesive employed in an absorbent article garment, inaddition to the associated machinery required for adhesive application.The lack of adhesive also has advantages relating to product benefitssuch as increased softness and unique visible patterning due to thediscrete bonds. The arcuate or curved elastomeric strands may provide abetter fit control.

In one embodiment, a method for forming an elasticated material maycomprise advancing a first continuous substrate material having an uppersurface and a lower surface in a machine direction, advancing a secondcontinuous substrate material having an upper surface and a lowersurface in the machine direction, and advancing an elastomeric strand ina stretched state in the machine direction, wherein the elastomericstrand is positioned between the lower surface of the first continuoussubstrate material and the upper surface of the second continuoussubstrate material. The method may further comprise advancing the firstcontinuous substrate material and the second continuous substratematerial with the elastomeric strand positioned therebetween to abonding apparatus. The bonding apparatus may comprise a first bondingelement and a second bonding element disposed proximate the firstbonding element and forming a bonding nip with the first bondingelement. The method may also comprise oscillating the elastomeric strandin a cross-machine direction, advancing the first continuous substratematerial, the second continuous substrate material, and the elastomericstrand through the bonding nip and bonding the first continuoussubstrate material to the second continuous substrate material with theelastomeric strand disposed therebetween with at least a first bond anda second bond. The first bond and the second bond may be disposed onopposite sides of the elastomeric strand and spaced apart a distanceless than an un-tensioned diameter of the elastomeric strand and may belocated along a portion of the elastomeric strand which extends in anarcuate manner.

In another embodiment, a method for forming an elasticated material maycomprise advancing a first continuous substrate material having an uppersurface and a lower surface in a machine direction, advancing a secondcontinuous substrate material having an upper surface and a lowersurface in the machine direction, advancing an elastomeric strand in astretched state in the machine direction, wherein the elastomeric strandis positioned between the lower surface of the first continuoussubstrate material and the upper surface of the second continuoussubstrate material, and advancing the first continuous substratematerial and the second continuous substrate material with theelastomeric strand positioned therebetween to a bonding apparatus. Thebonding apparatus may comprise a first bonding element, a second bondingelement disposed proximate the first bonding element and forming abonding nip with the first bonding element, and a guide element disposedproximate the second bonding element and forming a guide nip with thesecond bonding element. The method may further comprise oscillating theelastomeric strand in a cross-machine direction, advancing the secondcontinuous substrate and the elastomeric strand through the guide nip sothat the second continuous substrate and the elastomeric contact thesecond bonding element prior to the bonding nip, and advancing the firstcontinuous substrate material, the second continuous substrate material,and the elastomeric strand through the bonding nip and bonding the firstcontinuous substrate material to the second continuous substratematerial with the elastomeric strand disposed therebetween with at leasta first bond and a second bond. The first bond and the second bond maybe disposed on opposite sides of the elastomeric strand and spaced aparta distance less than an un-tensioned diameter of the elastomeric strandand located along a portion of the elastomeric strand which extends inan arcuate manner.

In a further embodiment, an elasticated material may comprise a firstsubstrate layer, a second substrate layer, an elastomeric stranddisposed between the first substrate layer and the second substratelayer, and a plurality of bonds bonding the first substrate layer to thesecond substrate layer. The elastomeric strand may comprise at least onestraight portion and at least one arcuate portion. The plurality ofbonds may comprise a first bond and a second bond, and the first bondand the second bond may be disposed on opposite sides of the elastomericstrand and spaced apart a distance less than an un-tensioned diameter ofthe elastomeric strand and located along an arcuate portion of theelastomeric strand.

The above summary of the present disclosure is not intended to describeeach embodiment or every implementation of the present disclosure.Advantages and attainments, together with a more complete understandingof the disclosure, will become apparent and appreciated by referring tothe following detailed description and claims taken in conjunction withthe accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments in connection withthe accompanying drawings, in which:

FIG. 1 is a plan view of an elasticated material according to aspects ofthe present disclosure;

FIG. 2 is a cross-section view of the elasticated material of FIG. 1 asviewed along line 2-2;

FIGS. 3A-3C are close-up views of the elasticated material of FIG. 1depicting different aspects of the present disclosure;

FIG. 4 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 5 is a schematic view of a process for forming elasticatedmaterials of the present disclosure;

FIG. 6 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 7 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 8 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 9 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 10 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 11 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 12 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 13 is a plan view of another elasticated material according toaspects of the present disclosure;

FIG. 14 is a schematic view of a process for forming elasticatedmaterials of the present disclosure;

FIG. 15 is another schematic view of a process for forming elasticatedmaterials of the present disclosure;

FIG. 16 is an exemplary absorbent article including elasticatedmaterials according to aspects of the present disclosure; and

FIG. 17 is another exemplary absorbent article including elasticatedmaterials according to aspects of the present disclosure.

While the disclosure is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit aspects of thedisclosure to the particular embodiments described. On the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the scope of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure is generally directed toward elasticatedmaterials and processes for forming elasticated materials having arcuateor curved elastomeric strands. In general, the elasticated materials maynot require adhesive to affix the elastomeric strands within thematerial. Although, it should be understood that in some embodiments theelasticated materials disclosed herein may benefit from applications ofadhesive as well. For instance, the elasticated materials may employlaminating adhesive to ensure consistent contact and minimal slippingbetween the materials of the elasticated materials. The presentdisclosure details a number of different material structures that can beformed by the described processes using different bonding patterns toaffix elastomeric strands in an arcuate or curved shape within anelasticated material.

Each example is provided by way of explanation and is not meant as alimitation. For example, features illustrated or described as part ofone embodiment or figure can be used on another embodiment or figure toyield yet another embodiment. It is intended that the present disclosureinclude such modifications and variations.

Although some suitable dimensions, ranges and/or values pertaining tovarious components, features and/or specifications are disclosed, one ofskill in the art, incited by the present disclosure, would understanddesired dimensions, ranges and/or values may deviate from thoseexpressly disclosed.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Many modifications and variations of the present disclosurecan be made without departing from the spirit and scope thereof.Therefore, the exemplary embodiments described above should not be usedto limit the scope of the invention.

Definitions

The term “absorbent article” refers herein to an article which may beplaced against or in proximity to the body (i.e., contiguous with thebody) of the wearer to absorb and contain various liquid, solid, andsemi-solid exudates discharged from the body. Such absorbent articles,as described herein, are intended to be discarded after a limited periodof use instead of being laundered or otherwise restored for reuse. It isto be understood that the present disclosure is applicable to variousdisposable absorbent articles, including, but not limited to, diapers,diaper pants, training pants, youth pants, swim pants, feminine hygieneproducts, including, but not limited to, menstrual pads or pants,incontinence products, adult diapers and pants, medical garments,surgical pads and bandages, other personal care or health care garments,and the like without departing from the scope of the present disclosure.

The term “bonded”, “attached” or “coupled” refers herein to the joining,adhering, connecting, attaching, or the like, of two elements. Twoelements will be considered bonded, attached or coupled together whenthey are joined, adhered, connected, attached, or the like, directly toone another or indirectly to one another, such as when each is directlybonded to intermediate elements. The bonding, attaching or coupling ofone element to another can occur via continuous or intermittent bonds.

The term “carded web” refers herein to a web containing natural orsynthetic staple length fibers typically having fiber lengths less thanabout 100 mm. Bales of staple fibers can undergo an opening process toseparate the fibers which are then sent to a carding process whichseparates and combs the fibers to align them in the machine directionafter which the fibers are deposited onto a moving wire for furtherprocessing. Such webs are usually subjected to some type of bondingprocess such as thermal bonding using heat and/or pressure. In additionto or in lieu thereof, the fibers may be subject to adhesive processesto bind the fibers together such as by the use of powder adhesives. Thecarded web may be subjected to fluid entangling, such ashydroentangling, to further intertwine the fibers and thereby improvethe integrity of the carded web. Carded webs, due to the fiber alignmentin the machine direction, once bonded, will typically have more machinedirection strength than cross machine direction strength.

The term “film” refers herein to a thermoplastic film made using anextrusion and/or forming process, such as a cast film or blown filmextrusion process. The term includes apertured films, slit films, andother porous films which constitute liquid transfer films, as well asfilms which do not transfer liquids, such as, but not limited to,barrier films, filled films, breathable films, and oriented films.

The term “gsm” refers herein to grams per square meter.

The term “hydrophilic” refers herein to fibers or the surfaces of fiberswhich are wetted by aqueous liquids in contact with the fibers. Thedegree of wetting of the materials can, in turn, be described in termsof the contact angles and the surface tensions of the liquids andmaterials involved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 are designated “wettable” orhydrophilic, and fibers having contact angles greater than 90 aredesignated “nonwettable” or hydrophobic.

The term “meltblown” refers herein to fibers formed by extruding amolten thermoplastic material through a plurality of fine, usuallycircular, die capillaries as molten threads or filaments into converginghigh velocity heated gas (e.g., air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter,which can be a microfiber diameter. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly dispersed meltblown fibers.Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 toButin et al., which is incorporated herein by reference. Meltblownfibers are microfibers which may be continuous or discontinuous, aregenerally smaller than about 0.6 denier, and may be tacky andself-bonding when deposited onto a collecting surface.

The term “nonwoven” refers herein to materials and webs of materialwhich are formed without the aid of a textile weaving or knittingprocess. The materials and webs of materials can have a structure ofindividual fibers, filaments, or threads (collectively referred to as“fibers”) which can be interlaid, but not in an identifiable manner asin a knitted fabric. Nonwoven materials or webs can be formed from manyprocesses such as, but not limited to, meltblowing processes,spunbonding processes, carded web processes, hydroentangling processes,etc.

The term “spunbond” refers herein to small diameter fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine capillaries of a spinnerette having a circular orother configuration, with the diameter of the extruded filaments thenbeing rapidly reduced by a conventional process such as, for example,eductive drawing, and processes that are described in U.S. Pat. No.4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al.,U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No.3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., eachof which is incorporated herein in its entirety by reference. Spunbondfibers are generally continuous and often have average deniers largerthan about 0.3, and in an embodiment, between about 0.6, 5 and 10 andabout 15, 20 and 40. Spunbond fibers are generally not tacky when theyare deposited on a collecting surface.

The term “elasticated” when used herein to describe a material or aportion of an article means that the material or article it is made ofan inelastic sheet material coupled to elastomeric material, e.g. one ormore elastomeric bands or strands, such that the material or articleexhibits elastic properties.

The term “thermoplastic” refers herein to a material which softens andwhich can be shaped when exposed to heat and which substantially returnsto a non-softened condition when cooled.

The term “user” or “caregiver” refers herein to one who fits anabsorbent article, such as, but not limited to, a diaper, diaper pant,training pant, youth pant, incontinent product, or other absorbentarticle about the wearer of one of these absorbent articles. A user anda wearer can be one and the same person.

Elasticated Material:

FIG. 1 is a top plan view depicting a portion of exemplary elasticatedmaterial 10. The elasticated material 10 generally extends in both thelongitudinal direction 31, between a top sheet edge 11 and a bottomsheet edge 13, and the lateral direction 32. The elasticated material 10may generally comprise a first layer of material 12, a second layer ofmaterial 14, elastomeric strands 16, and bonds 20. As will be describedin more detail below, at least some of the bonds 20 may be positioned onopposite sides of the elastomeric strands 16 in such a manner that thebonds 20 affix, or “entrap”, portions of the elastomeric strands 16 inplace within the elasticated material 10.

FIG. 3A depicts a close-up view of circle 33 of FIG. 1 , detailing thebonds 20 and one of the elastomeric strands 16 of the elasticatedmaterial 10 in more detail, showing the entrapping of the depictedelastomeric strand 16. Specifically, FIG. 3A depicts the outer edges ofthe elastomeric strand 16 with dashed lines as the strand 16 passesbetween pairs of bonds 20, such as bonds 20 a and 20 b which entrap thestrand 16. As can be seen, the elastomeric strand 16 in FIG. 3A may havenon-entrapped portions 21 and entrapped portions 22, which alternatealong the lateral length of the elastomeric strand 16.

In order to form a material such as the elasticated material 10, withelastomeric strands 16 entrapped within between the layers of material12, 14, the elastomeric strands 16 may be stretched before or as theelastomeric strands 16 are positioned between the first layer ofmaterial 12 and the second layer of material 14. The elastomeric strands16 may have an un-tensioned outer diameter, and the outer diameter ofthe elastomeric strands 16 may decrease as the strands 16 are stretched.Accordingly, before or at the time the strands 16 are placed between thefirst layer of material 12 and the second layer of material 14, theelastomeric strands 16 may have an outer diameter that is less thantheir un-tensioned outer diameter. Then, at least a pair of the bonds 20of the material 10, for example bonds 20 a, 20 b in FIG. 3A, may beplaced on opposite sides of the stretched elastomeric strand 16 andspaced apart longitudinally across the strand 16 a longitudinal distance25. In some embodiments, the longitudinal distance 25 may beapproximately equal to the outer diameter of the strand 16 at the timethe bond pair 20 a, 20 b is formed. In other embodiments, thelongitudinal distance 25 may be greater than the outer diameter of thestrand 16 at the time the bond pair 20 a, 20 b is formed, but less thanthe outer diameter of the un-tensioned diameter of the strand 16.

As the elastomeric strands 16 of the elasticated material such asmaterial 10 are allowed to relax, the outer diameter of the elastomericstrands 16 generally increases back toward their un-tensioned outerdiameter. However, as can be seen in FIG. 3A, this expansion isinhibited in the entrapped portions 22 of the elastomeric strand 16 bythe bonds 20 which are positioned across the strands 16 a longitudinaldistance less than the un-tensioned diameter of the strands 16, such asbond pairs 20 a, 20 b and 20 d, 20 e and the like. As the elastomericstrand 16 of FIG. 3A relaxes and contracts from a stretched state, thenon-entrapped portions 21 of the elastomeric strand 16 expands in thelongitudinal direction 31 (e.g. the outer diameter of the elastomericstrand 16 increases), resulting in the structure as seen in FIG. 3A withthe elastomeric strand 16 shown having expanded outer diameter 23 in thenon-entrapped portions 21. The entrapped portions 22 result in theelastomeric strand 16 being affixed in place within the material 10.

The relaxation of the elastomeric strands 16 causes contraction of thestrands 16 between entrapped portions 22. This contraction causescorresponding valleys 15 and ridges 17 to form within the elasticatedmaterial 10. The structure of the elasticated material 10, including thevalleys 15 and the ridges 17, may be seen more clearly in FIG. 2 , whichis a cross-section of the elasticated material 10 of FIG. 1 , as viewedalong line 2-2 which extends perpendicular to the ridges 15 and valleys17 of the elasticated material 10.

In some embodiments, the expanded diameter 23 of the elastomeric strand16 may be the same as the un-tensioned diameter of the elastomericstrand 16, but in other embodiments this may not be the case. Forexample, the specific configuration of the type of elastomeric strand16, the amount of elongation of the elastomeric strand 16 in the formingprocess, and the location of the bonds 20 in relation to the elongatedelastomeric strand 16, both in the longitudinal distance 25 betweenbonds 20 that span the elastomeric strand 16 and/or in the lateraldistance between bonds 20, may prevent the diameter of the elastomericstrand 16 from expanding in the non-entrapped portions 21 all the wayback to the un-tensioned diameter of the strand 16. Accordingly, in someembodiments the expanded diameter 23 in the non-entrapped portions 21 ofat least some of the elastomeric strands 16 of the material 10 may stillbe less than the un-tensioned diameter of the elastomeric strands 16.

Accordingly, in the above manner, the elastomeric strands 16 may beentrapped within the elasticated material 10. Additionally, as can beseen in FIG. 1 , in some embodiments the elasticated material 10 mayinclude entrapped elastomeric strands 16 extending through the material10 in a generally arcuate manner. Having elastomeric strands 16 extendthrough the material 10 in a generally arcuate manner may providedesired stretch properties in the material 10. As one example, thearcing elastomeric strands 16 may allow for better fit of an articleutilizing the material 10.

As used herein, the term “arcuate” or “generally arcuate” encompassesthe general shape the portions of the elastomeric strands 16 form wherethe strands 16 extend in both the lateral and longitudinal directions31, 32 through the elasticated materials of the present disclosure. Forinstance, as shown in FIG. 1 , the elastomeric strands 16 comprisegenerally arcuate portions 18. In some embodiments, the elasticatedmaterials of the present disclosure may comprise straight portions 19.Straight portions may be defined as portions of the strands 16 whichextend in substantially a single direction (generally the lateraldirection 31) for an appreciable distance without extending in aseparate, second direction (such as the longitudinal direction 32)—suchas more than about 5 mm or more than about 10 mm or more than about 15mm.

In some embodiments of elasticated materials contemplated by the presentdisclosure, the one or more elastomeric strands 16 may have a generallycontinuous arcuate shape where the strands 16 do not comprise straightportions 19. In other contemplated embodiments, the strands 16 mayalternate between arcuate portions 18 and straight portions 19. One suchembodiment, shown in FIG. 1 , comprises elastomeric strands 16 havingstraight portions 19, with the arcuate portions 18 disposed between thestraight portions 19.

In general, longitudinally adjacent bonds of the bonds 20 may form bondpairs defining un-bonded channels 24 extending between the bond pairs.In the embodiment of FIG. 1 , multiple bond pairs are arranged inlaterally extending rows to provide laterally extending un-bondedchannels 24. Because the arcuate portions 18 include the strands 16extending in both the lateral and the longitudinal directions 31, 32,the arcuate portions 18 of the strands 16 may extend through multipledifferent, longitudinally adjacent un-bonded channels 24. In the exampleof FIG. 1 , the top elastomeric strand left-side arcuate portion 18extends through un-bonded channel 24 e and through longitudinallyadjacent un-bonded channel 24 d. This arcuate portion 18 further extendsthrough un-bonded channel 24 c, which is longitudinally adjacent to theun-bonded channel 24 d. This arcuate portion 18 still further extendsthrough un-bonded channels 24 b and 24 a. The right-hand side arcuateportion 18 extends through un-bonded channel 24 a and then back throughun-bonded channels 24 b, 24 c, 24 d, and finally back to un-bondedchannel 24 e. Although called out as separate arcuate portions 18 in theabove description, the two described arcuate portions 18 may beconsidered a single arcuate portion 18, as no straight portion isdisposed between the two arcuate portions 18.

In some embodiments where an elastomeric strand 16 comprises multiplestraight portions 19 with at least one arcuate portion 18 disposedtherebetween, the elastomeric strand 16 may extend through the same,first un-bonded channel 24 along the straight portions 19 located priorto and after the one or more arcuate portions 18. For example, as seenin FIG. 1 , the top elastomeric strand 16 is shown extending throughun-bonded channel 24 e along both straight portions 19. In otherembodiments, however, the elastomeric strand 16 may extend throughdifferent un-bonded channels 24 along the first and second straightportions 19. For instance, in different embodiments of material 10, thefirst (left-hand side) straight portion 19 of the strand 16 may extendthrough un-bonded channel 24 e and the second (right-hand side) straightportion 19 may extend through un-bonded channel 24 d, or 24 f, or anyother un-bonded channel of the material 10.

Along arcuate portions 18, there is really no limit to the number oflongitudinally adjacent un-bonded channels 24 through which theelastomeric strands 16 may extend. Although the strands 16 shown in FIG.1 are depicted as extending through only five different un-bondedchannels 24 along the arcuate portions 18, this should not be construedas limiting in any fashion. The number of un-bonded channels 24 throughwhich a strand 16 may extend along its arcuate portions 18 may generallybe a design decision dictated by the ultimate purpose of the material10.

Additionally, there is also no lower limit to the number of bond pairsthrough which an elastomeric strand 16 needs to extend in a givenun-bonded channel 24 along its arcuate portions 18. For instance, FIG. 1shows the elastomeric strands 16 extending through as few as zero bondpairs in a given un-bonded channel, such as channel 24 b, and as many asthree bond pairs in another un-bonded channel, such as channel 24 a.However, these numbers should not be viewed as upper and lower limits.In some preferred embodiments, it may be desirable that the strands 16extend through at least one, or at least two, or at least three, or atleast four, or at least five, bond pairs in each un-bonded channel 24along arcuate portions 18.

A few contemplated apparatuses and processes for forming the strands 16with arcuate portions 18 and how to form the bonds 20 with minimalinstances of strand breakage will be described in more detail withrespect to other of the Figures of the present disclosure.

Web Materials:

In general, the first layer of material 12 and the outer layer ofmaterial 14 may be constructed of any materials suitable for use inwaistbands, leg cuffs, or any other body-contacting portions, ornon-body-contacting portions, of clothing garments and absorbentarticles. The layers 12, 14 may be constructed of the same material ordifferent materials. Each of the layers 12, 14 may comprise a singlelayer, multiple layers, laminates, or the like in different contemplatedembodiments. Additionally, the layers 12, 14 may comprise two separatewebs of material positioned on opposite sides of the elastomeric strands16 to form the elasticated material 10, or the layers 12, 14 maycomprise a single web of material that is folded over such that a firstportion of the web of material is positioned on a first side of theelastomeric strands 16 and a second portion of the web of material ispositioned on a second side of the elastomeric strands 16 to form theelasticated material 10.

Exemplary suitable classes of materials for the layers 12, 14, includesynthetic fibers (for example, polyethylene or polypropylene fibers),natural fibers (for example, wood or cotton fibers), a combination ofnatural and synthetic fibers, porous foams, reticulated foams, aperturedplastic films, or the like. Examples of suitable materials include, butare not limited to, rayon, wood, cotton, polyester, polypropylene,polyethylene, nylon, or other heat-bondable fibers, polyolefins, suchas, but not limited to, copolymers of polypropylene and polyethylene,linear low-density polyethylene, and aliphatic esters such as polylacticacid, finely perforated film webs, net materials, and the like, as wellas combinations thereof.

Additionally, various woven and non-woven fabrics can be used for thelayers 12, 14. The layers 12, 14 can comprise woven fabrics, nonwovenfabrics, polymer films, film-fabric laminates or the like, as well ascombinations thereof. Examples of nonwoven fabrics can include spunbondfabrics, meltblown fabrics, coform fabrics, carded webs, bonded-cardedwebs, bicomponent spunbond fabrics, spunlaces, or the like, as well ascombinations thereof.

For example, the layers 12, 14 can be composed of a meltblown orspunbond webs of polyolefin fibers. Alternatively, the layers 12, 14 canbe bonded-carded webs composed of natural and/or synthetic fibers. Thelayers 12, 14 can be composed of a substantially hydrophobic materials,and the hydrophobic materials can, optionally, be treated with asurfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. The surfactant can be applied to the entirety of the layers 12, 14or it can be selectively applied to particular sections of the layers12, 14. Some specific exemplary materials suitable for the layers 12, 14include 100% polypropylene bonded-carded webs in the 5-150 gsm range.Other exemplary suitable materials include spunbond polypropylenenon-woven webs in the 5-150 gsm range. Still other exemplary materialsmay have basis weights above 150 gsm.

In an embodiment, the layers 12, 14 can be constructed of a non-wovenbicomponent web. The non-woven bicomponent web can be a spunbondedbicomponent web, or a bonded-carded bicomponent web. An example of abicomponent staple fiber includes a polyethylene/polypropylenebicomponent fiber. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Fibers having other orientations, such as multi-lobe,side-by-side, end-to-end may be used without departing from the scope ofthis disclosure. In an embodiment, the layers 12, 14 can be spunbondsubstrates with a basis weight from about 8 to about 50 gsm. In anembodiment, the layers 12, 14 can be a 12 gsmspunbond-meltblown-spunbond substrate. In another embodiment, the layers12, 14 can be an 8 gsm spunbond-meltblown-spunbond substrate.

Elastomeric Strands:

Suitable elastomeric materials for the elastomeric strands 16 caninclude, but are not limited to, spandex elastomeric strands, strands ofnatural or synthetic rubber, thermoplastic elastomeric materials, orheat activated elastomeric materials. The elastomeric strands 16 can beany elastomeric material capable of being elongated at least about 50percent, desirably about 350 percent, and capable of recovering towithin at least about 250 percent, and desirably about 150 percent ofits original length after being elongated about 300 percent. Theelastomeric strands 16 can be a spandex elastomeric strand(s) such as,for example, a LYCRA thread commercially available from E. I. DuPont deNemours and Co. Alternatively, the elastomeric strands 16 can becomposed of a thermoplastic elastomer or a natural or a synthetic rubbercommercially available from J.P.S. Elastomerics Corp. Alternatively, theelastomeric strands 16 can also be composed of a heat activated elasticmaterial such as PEBAX, commercially available from Atochem, Inc., whichcan be activated with heat treatment after the elastomeric strands 16have been disposed within the elasticated material 10 and the bonds 20have been formed. In at least some embodiments, the elastomeric strandsmay have diameters that range between about 10 denier to about 1500denier.

Bonds:

The bonds 20 can be formed through any suitable bonding technique, suchas thermal/heat bonding, ultrasonic bonding, pressure bonding, or otherknown bonding techniques. In general, as will be described in moredetail below, the bonds 20 can be formed by use of a pattern componentand a smooth component. To form the bonds 20, the layers 12, 14, withthe elastomeric strands 16 disposed therebetween, are positioned betweenthe pattern component and the smooth component with appropriatealignment between any features of the pattern component and theelastomeric strands 16. For instance, the elastomeric strands 16 may bepositioned between raised protrusions (e.g. bond-forming protrusions) ofthe pattern component.

For instance, where thermal bonding, pressure bonding, or rotaryultrasonic bonding techniques are used to form the bonds 20, the patterncomponent and the smooth component may be pattern rolls and smoothrolls, respectively. In such embodiments, the pattern rolls may containa number of raised portions that protrude from the surface of thepattern rolls. The raised portions may correspond approximately with theshape of the bonds 20 and aligned on the surface of the pattern rolls toproduce the longitudinal and latitudinal alignment of the bonds 20 asdepicted in the different embodiments of the elasticated materials ofthe present disclosure. The smooth rolls may generally be solid rollswith smooth outer surfaces.

The heat bonding techniques which may be used to form the bonds 20 mayinclude heating the raised portions of the pattern rolls to betweenabout 70 degrees C. and about 340 degrees C. In general, the level ofheating should be less than that which results in melting of theelastomeric strands 16 when the bonds are being formed. While the raisedportions are at the appropriate temperature, the pattern roll may bepressed onto the smooth roll, with the layers 12, 14 and the elastomericstrands 16 positioned between the rolls. As some examples, thecompressive force used to form the bonds 20 may be between about 500 KPaand about 2,750 KPa, and the layers 12, 14 and the elastomeric strands16 may pass between the pattern and anvil rolls between about 100 linearmeters per minute (mpm) and about 350 (mpm).

The rotary ultrasonic bonding techniques that may be used to form thebonds 20 may use ultrasonic energy in order to form the bonds 20. Forinstance, as the layers 12, 14 and the elastomeric strands 16 passbetween the pattern roll and smooth roll of a rotary ultrasonic bonder,the smooth roll may be vibrated at a frequency of between about 20,000Hz and about 50,000 Hz, causing internal heating of the layers 12, 14 tosuch an extent that the layers 12, 14 melt together forming the bonds20.

The pressure bonding techniques which may be used to form the bonds 20may be similar to the heat bonding techniques described above, exceptthat no external heat may need to be applied to the raised portions ofthe pattern roll. However, in order to compensate for the raisedportions only being at an ambient temperature, the compressive forceapplied to the pattern roll and the smooth roll to form the bonds 20must be greatly increased. In some examples, the compressive force isapplied to produce a nip force between about 0.1KN and about 5 KN, whilethe layers 12, 14 and the elastomeric strands 16 pass between thepattern roll and the anvil roll at about 15 mpm and 450 mpm.

In non-rotary ultrasonic bonding techniques that may be used to form thebonds 20, the pattern element and the anvil element may be a smoothultrasonic horn and a patterned anvil. In such embodiments, the anvilcomponent may have the raised portions, while the ultrasonic horn has agenerally smooth surface. In some embodiments, the patterned anvil maybe a flat plate, while in other embodiments multiple patterned anvilsmay be spaced around a circumference of a drum and timed to coincidewith “strikes” of the ultrasonic horn. In still other embodiments, thepatterned anvil may comprise a circular drum with raised protrusionsdisposed on the surface of the drum. Like with the rotary ultrasonictechniques, the ultrasonic horn may be vibrated at a frequency ofbetween about 20,000 Hz and about 50,000 Hz, as the layers 12, 14 andthe elastomeric strands 16 pass between the ultrasonic horn and thepatterned anvil. This ultrasonic energy application causes internalheating of the layers 12, 14 to such an extent that the layers 12, 14melt together forming the bonds 20.

In general, such heat bonding techniques, ultrasonic bonding techniques,and pressure bonding techniques known in the art. It should beunderstood that the parameters described for the different techniquesare only exemplary suitable parameters. The described techniques may beused to form the bonds 20 using such techniques operating with othersuitable parameters, as is known in the art. For instance, PCT PatentApplication WO 2010/068150, titled “METHOD AND APPARATUS FOR BONDING”,which is incorporated herein by reference in its entirety, detailsmethods and apparatus for performing pressure bonding which could beused to form the bonds 20 of the bond patterns described in the presentdisclosure using many different suitable parameters. It shouldadditionally be understood that the different ways in which the bonds 20are formed do not appreciably affect the resulting structure of theelasticated material, aside from possibly resulting in differentstrengths of the bonds 20. However, all of such known techniques arecapable of producing bonds which are strong enough to resist theexpansion of the elastomeric strands positioned between the bonds 20without the bonds 20 breaking. Accordingly, the bonds 20 may be formedaccording to any known bonding technique without departing from thescope of the present disclosure.

In general, the bonds 20 of the elasticated materials 10 of the presentdisclosure may have any suitable size or shape. However, in at leastsome embodiments, the bonds 20 may have areas ranging between about 50square micrometers to about 20 square millimeters, or between about 70square micrometers to about 10 square millimeters, or between about 250square micrometers and about 5 square millimeters. Additionally, in someembodiments, the dimension of the bonds 20 in a direction generallyparallel to the elastomeric strands 16, e.g. lateral length dimension42, may be between about two times to about six times greater than thedimension of the bonds 20 that is generally perpendicular to theelastomeric strands 16, e.g. longitudinal height dimension 44. Forinstance, in the embodiment of FIG. 3A, a lateral length oflaterally-extending portions of the bonds 20 (e.g. portions 34, 36) maybe between about two times and about six times greater than alongitudinal height of longitudinally-extending portions of the bonds 20(e.g. portions 35, 37).

Additionally, it should also be understood that the bonds may generallyhave any longitudinal and/or lateral spacing. For instance, thelongitudinal spacing of longitudinally adjacent bonds of the bonds 20,such as 20 a and 20 b or 20 a and 20 c of FIG. 3A, may vary depending onwhether an elastomeric strand 16 is disposed between the longitudinallyadjacent bonds. In some embodiments, the longitudinal spacing betweenlongitudinally adjacent bonds 20 a and 20 b, as represented bylongitudinal distance 25, may be less than the longitudinal spacingbetween longitudinally adjacent bonds 20 a and 20 c, represented bylongitudinal distance 26, where no elastomeric strand 16 is disposedbetween bonds 20 a, 20 c. As an example, the longitudinal distance 25may be less than the un-tensioned diameter of the elastomeric strand 16,while the longitudinal distance 26 may have any suitable longitudinalspacing including a spacing that is greater than the un-tensioneddiameter of any elastomeric strands 16 of the material 10. Suchembodiments may allow for a sparser bond pattern in regions of thematerial 10 where no elastomeric strand 16 is entrapped. Although, infurther embodiments, the longitudinal distances 25, 26 may be the sameeven where an elastomeric strand 16 extends between bonds 20 a, 20 b,but no elastomeric strand 16 extends between bonds 20 a, 20 c. In someillustrative examples, the longitudinal distance between longitudinallyadjacent bonds 20 between which no elastomeric strand 16 extends (suchas bonds 20 a, 20 c) may vary between about 1 mm and about 500 mm.

The lateral spacing between laterally adjacent bonds of the bonds 20 maybe the same throughout the material 10 or may be varied. For instance,in some embodiments the lateral spacing between laterally adjacent bonds20 which are located adjacent an elastomeric strand 16 (e.g. bonds 20 a,20 d), as represented by lateral distance 38, may be less than thelateral spacing between laterally adjacent bonds 20 which are notlocated adjacent an elastomeric strand 16 (e.g. bonds 20 c, 20 e), asrepresented by lateral distance 39. Although, in other embodiments, thelateral distances 38 and 39 may be the same. Additionally, in someembodiments, the lateral spacing between laterally adjacent bonds 20 mayvary even between pairs of laterally adjacent bonds 20 which areadjacent an elastomeric strand 16. For instance, when used in a garmentor absorbent article, the lateral spacing of bonds 20 may be variedthroughout different regions of the garment or article to impart adesired pattern or softness to the material. As some non-limitingexamples, the lateral spacing between laterally adjacent bonds of thebonds 20 may vary between about 1 mm and about 500 mm.

FIG. 3A details additional features of bonds 20. For instance, bonds 20may each include a top portion 34, a bottom portion 36 opposite the topportion 34, a first side portion 35, and a second side portion 37opposite the first side portion 35. As can be seen, in at least someembodiments, the first side portions 35 of the bonds 20 are angled withrespect to the elastomeric strands 16. For instance, the first sideportion 35 of bond 20 a can be seen forming angle 40 with respect to alateral axis 28 of the elastomeric strand 16. The angling of the firstside portions 35 of the bonds 20 may provide the material with desirablestretch properties and may be beneficial for manufacture of the material10. In such embodiments, the angle 40 may range anywhere between about 1degree and about 179 degrees. In some more specific embodiments, theangle 40 may range between about 15 degrees and about 90 degrees, orbetween about 30 degrees and about 89 degrees, or between about 50degrees and about 88 degrees. In other embodiments, the angle 40 mayrange between about 105 degrees and about 180 degrees, or between about120 degrees and about 179 degrees, or between about 140 degrees andabout 178 degrees.

Additionally, as can be seen in FIG. 3A, in at least some embodimentsthe top portions 34 and the bottoms portions 36 of laterally adjacentbonds of the bonds 20 may generally align. However, in otherembodiments, the top portions 34 and bottom portions 36 of laterallyadjacent bonds may not generally align, and instead may form a staggeredpattern.

Although shown as generally rectangular, and more specifically asparallelograms, the bonds may be any suitable shape. FIGS. 3B and 3Cdepict alternatively shaped bonds 20 contemplated by the presentdisclosure—circles and squares, specifically. In still furthercontemplated embodiments, however, the bonds 20 may be semi-circular,oval shaped, half-oval shaped, triangular, rectangular, trapezoidal,rhombus-shaped, or the like. In some embodiments, the bonds 20 can havethree sides, four sides, five sides, six sides, or any other suitablenumber of sides.

FIG. 4 depicts an alternative elasticated material 10′ of the presentdisclosure as having a different pattern of the bonds 20 than thepattern of the bonds 20 of material 10 of FIG. 1 . As can be seen inFIG. 4 , the different bonds 20 may have different angles which theyform with respect to the lateral direction 32. Moving from the top sheetedge 11 to the bottom sheet edge 13, bonds 20 within a first grouping ofbonds, bond grouping 41, may each form a first angle 40 with respect tothe lateral direction 32, while bonds 20 within a second grouping ofbonds, bond grouping 43, which are laterally adjacent to the bondgrouping 41, may each form a second, different angle 40′ with respect tothe lateral direction 32. Although each of the bond groupings 41, 43 areshown as comprising four individual bonds 20, it should be understoodthat there is no real limit to the number of bonds 20 which may be in abond grouping. The number of bonds 20 in a bond grouping such asgroupings 41, 43 may be any suitable number—for example as few as one oras many as one-thousand.

This pattern may be repeated down to the bottom sheet edge 13. In someof these embodiments, the different angles 40 formed by the bonds withinthe bond groupings 41, 43, may mirror each other about the longitudinaldirection 31 such that the angle 40′ formed by each of the bonds 20 ofthe second bond grouping 43 is 180 degrees minus the value of the angle40 formed by the bonds 20 of the first bond grouping 41 (or vice-versaif the angle 40 formed by the bonds 20 of the first bond grouping 41 isgreater than the angle 40′ formed by the bonds 20 of the second bondgrouping 43). Such a pattern of bonds 20 as shown in FIG. 4 may providethe material 10′ with beneficial stretch properties, such as havesymmetrical stretch properties.

It should be understood that the patterns of bonds 20 of the materials10, 10′ as shown in FIGS. 1 and 4 should not be construed as limitingthe scope of the present disclosure. Rather, any pattern of bonds 20 maybe used in combination with this disclosure to produce elasticatedmaterials having elastomeric strands 16 forming generally curved shapes.For example, P.C.T. Application No. PCT/US2017/029845, filed on Apr. 27,2017 and titled “ELASTICATED MATERIALS WITH DIRECTIONAL STRETCHPROPERTIES”, the entirety of which is hereby incorporated by reference,details a number of patterns of bonds, all of which could be employedalong with the details of the present disclosure to form elasticatedmaterials having elastomeric strands forming generally curved shapes.

FIG. 5 is a schematic depiction of an apparatus for practicing anexemplary process 100 for forming the elasticated materials according tothe present disclosure. According to the process 100, a first layer ofmaterial 12 is fed, in the machine direction 132, between bondingelements 52 and 54 along with a second layer of material 14. One or moreelastomeric strands 16 are also fed between the elements 52, 54 and aredisposed between the layers 12, 14.

In the embodiment of FIG. 5 , the bonding element 52 represents a smoothroll and is shown adjacent bonding element 54 forming a bonding nip 56.The bonding element 54 represents a pattern roll which comprises raisedprotrusions forming a pattern corresponding to a desired bond pattern ofthe formed elasticated material 10. The layers of material 12, 14 andthe elastomeric strands 16 may come together at least at bonding nip 56,where the first layer of material 12 is bonded to the second layer ofmaterial 14, with the elastomeric strands 16 disposed therebetween, bythe bonding elements 52, 54. The type of bonding employed by the bondingelements 52, 54 may be any of the bonding types described previously inrelation to the details about the bonds 20 and forming the bonds 20, orany other suitable type of bonding. Of course, in embodiments where thebonds 20 are formed according to different bonding modalities, thebonding elements 52, 54 may not be rolls where necessitated by thespecific bonding modality. For example, the bonding element 52 maycomprise a smooth non-rotary ultrasonic element while the bondingelement 54 comprises a patterned rotary anvil element where a non-rotaryultrasonic bonding modality is employed.

According to the process 100, one or more of the elastomeric strands 16may further be oscillated across the face of the bonding element 54, inthe cross-machine direction 131, by oscillating device 57. Oscillatingdevice 57 may comprise any conventional device commonly used tooscillated elastomeric strands. This oscillation of the one or moreelastomeric strands 16 forms the one or more arcuate portions 18 of theone or more strands 16, with the generally arcuate shape of the portions18 held in place once the material 12 is bonded to the material 14.

One challenge in forming the generally arcuate or curved shape of theone or more elastomeric strands 16 is that the oscillation of the one ormore elastomeric strands 16 causes the one or more elastomeric strands16 to cross over the raised protrusions of the bonding element 54. Ifany of the one or more elastomeric strands 16 crosses over a raisedprotrusion of the bonding element 54 at the nip 56, the raisedprotrusion may compress the one or more elastomeric strands 16 againstthe bonding element 52 and break or otherwise damage the one or moreelastomeric strands 16. In this manner, forming elasticated materialswith elastomeric strands having a generally curved shaped is moredifficult than forming elasticated materials with elastomeric strandsextending in a generally straight manner because, in the lattermaterials, the elastomeric strands may be more easily aligned betweenthe raised protrusions prior to the bonding nip 56.

One option for decreasing the frequency of breakage or damage to theelastomeric strands 16 within the process 100 is to use bond patternswhich form entrapping regions and non-entrapping regions within theelasticated material. In such embodiments, the oscillator 57 may beconfigured to oscillate the one or more elastomeric strands 16 so as toalign the arcuate portions 18 within the portions of the bonding element54 comprising raised protrusions which have a pattern forming thenon-entrapping regions of the elasticated material. The non-entrappingregions may generally have a lower average bonded area than the averagebonded area of the entrapping regions. The lower average bonded areameans less opportunity for the elastomeric strands to align with theraised protrusions of the bonding element 54 as the bonds 20 are formedduring the bonding process 100. Accordingly, in such embodiments, thereis less opportunity for breakage of the strands 16 during formation ofthe bonds 20.

The elasticated materials 10 and 10′ of FIGS. 1-4 depict embodimentswhere the one or more elastomeric strands 16 have arcuate portions 18,and where the bonds 20 form un-bonded channels 24 which entrap the oneor more elastomeric strands 16 both along their arcuate portions 18 andalong their straight portions 19. That is, the bonds 20 disposed alongthe arcuate portions 18 (and the straight portions 19) of the strands 16are disposed such that pairs of the bonds 20 disposed on opposite sidesof the strands 16 along their arcuate portions 18 are spaced apart adistance less than an un-tensioned diameter of the elastomeric strands16. As mentioned, such materials 10, 10′ can be somewhat difficult tomanufacture, particularly at high speeds, due to breakage of the strands16 during manufacture.

FIGS. 6-12 depict other contemplated embodiments of the presentdisclosure which comprise elasticated materials having bothnon-entrapping regions 118 and entrapping regions 119, with thenon-entrapping regions 118 aligned with the arcuate portions 18 of theone or more elastomeric strands 16. Such embodiments may be relativelyeasier to manufacture and/or result in less breakage of the strands 16during manufacture due to the lower average bonded area within thenon-entrapping regions 118, as will be described in more detail belowwith respect to the different embodiments. The lower average bonded arearefers to the fact that, within a given section within a non-entrappingregion 118, the ratio of the total amount of bonded area (e.g. bondingthe first layer 12 to the second layer 14) to the total area of thegiven section will be less than the ratio of the total amount of bondedarea to the total area within a same-sized section disposed within anentrapping region 119.

As one example, FIG. 6 depicts exemplary elasticated material 200comprising elastomeric strands 16 having arcuate portions 18. Like theexemplary materials 10, 10′, the elastomeric strands 16 of the material200 include both arcuate portions 18 and straight portions 19. However,unlike the materials 10, 10′, the arcuate portions 18 of the elastomericstrands 16 extend through non-entrapping region 118. The bonds withinthe non-entrapping region 118 are labeled as bonds 201, and the bonds201 have a different size than the bonds 20 which are disposed in theentrapping regions 119. More specifically, as shown in FIG. 6 , thelongitudinal height 209 of the bonds 201 may be less than thelongitudinal height of the bonds 20 (e.g. height 44 as shown in FIG.3A). As can be seen, this creates a larger longitudinal spacing betweenlongitudinally adjacent bonds of the bonds 201, noted by longitudinalspacing 207, than the longitudinal spacing 25 of longitudinally adjacentbonds of the bonds 20 (as shown in FIG. 3A). Accordingly, in suchembodiments as those similar to elasticated material 200, thelongitudinal spacing 207 may be greater than an un-tensioned diameter ofthe elastomeric strands 16. In this manner, the non-entrapping region118 comprising the bonds 201 may not allow for entrapment of theelastomeric strands 16 along their arcuate portions 18.

The non-entrapping regions 118 may be defined as the regions of thematerial 200 containing the bonds 201 which differ in size than thebonds 20, and where the differing size of the bonds 201 results in alongitudinal spacing 207 between longitudinally adjacent bonds 201 suchthat the bonds 201 do not allow for entrapment of the strands 16.Conversely, the entrapping regions 119 may be defined as the regions ofthe material 200 where the bonds 20 comprise a longitudinal spacing 25between longitudinally adjacent bonds 20 which allows for entrapment ofthe strands 16.

The smaller dimension bonds 201 of the material 200 may help to preventbreakage of the elastomeric strands 16 during manufacture. For example,the effect of the smaller bond dimensions of the bonds 201 results in arelatively smaller average bonded area within the non-entrapping regions118 of the material 200 through which the strands 16 may extend in agenerally arcuate manner. This is in contrast to the relatively largeraverage bonded area of the regions of the materials 10, 10′ throughwhich the strands 16 extend in a generally straight manner. In someembodiments, the average bonded area of the material 200 in theentrapping regions 119 may be between about 5% to about 40%, or betweenabout 5% and about 20%, or between about 10% and about 20%. The averagebonded area of the material 200 in the non-entrapping regions may bebetween about 1% to about 10%. The smaller average bonded area of thenon-entrapping regions 118 results in a lower chance that the strands 16and the raised protrusions of the bonding element 54 which form thebonds 201 will align during the formation of the bonds 201. Accordingly,there is less chance that the process of bonding the layers 12 and 14together will result in breakage of the strands 16.

Another way to define the materials of the present disclosure is bylateral regions. For example, the material 200 of FIG. 6 may be dividedby longitudinal lines into separate lateral regions, such as lateralregions 128 and 129. The lateral regions 129 may be entrapping regionswhere the elastomeric strands within the regions 129 are entrapped,while the lateral regions 128 may be non-entrapping regions where theelastomeric strands are not entrapped (or at least not entrapped along amajority of their length within the regions 128). In such embodiments,the average bonded area within each of the regions 128, 129 may bedifferent as described above. Generally, the average bonded area withinthe non-entrapping regions 128 may be less than the average bonded areawithin the entrapping regions 129. The average bonded area in theentrapping regions 129 may be between about 5% to about 40%, or betweenabout 5% and about 20%, or between about 10% and about 20%. The averagebonded area in the non-entrapping regions 128 may be between about 1% toabout 10%.

Referring to material 200 of FIG. 6 , although the one or moreelastomeric strands 16 are not entrapped within the non-entrappingregion 118 of the material 200, the bonds 201 maintain the generallyarcuate or curved shape of the strands 16 within the non-entrappingregion 118. For example, the material 200 is formed with the strands 16under tension. When the material 200 is allowed to relax, the strands 16will retract and press against the bonds 201, thereby maintaining thedesired generally arcuate or curved shape of the strands 16 andimparting the material 200 with the desired stretch properties.

The embodiment of material 200 in FIG. 6 shows the bonds 201 in thenon-entrapping region 118 as generally aligning with laterally adjacentbonds 20 within the entrapping regions 119. For example, the topportions 34 of the bonds 201 and the bonds 20 generally align betweenlaterally adjacent bonds of the bonds 201, 20. This is similar to thealignment of the bonds 20 in the described materials 10, 10′. However,the bonds 201, 20 do not need to align in this manner in allcontemplated embodiments. For instance, FIG. 7 depicts another exemplarymaterial, material 200′, including one or more elastomeric strands 16having a generally arcuate or curved shape. In the embodiment of FIG. 7, however, the bonds 201 in the non-entrapping regions 118 do not alignwith laterally adjacent bonds 20 in the entrapping regions 119 as in thematerials 10, 10′, and 200. As can be seen, the top portions 34 of thebonds 201, in the embodiment of material 200′, do not align with the topportions 34 of laterally adjacent bonds 20. Instead, the bonds 201 aredisposed such they are generally centered in the longitudinal direction31 between top portions 34 and bottom portions 36 of laterally adjacentbonds 20.

Still further embodiments are contemplated by the present disclosurewhere one or more elastomeric strands extend through a non-entrappingregion of an elasticated material in a generally arcuate or curved shapewithout being entrapped between bonds within the non-entrapping region.For example, instead of the bonds within a non-entrapping region havingdifferent dimensions than bonds outside of the non-entrapping region,additional elastomeric materials of the present disclosure arecontemplated where the spacing between bonds within the non-entrappingregion are different than the spacing between bonds outside of thenon-entrapping region.

FIGS. 8 and 9 depict additional exemplary materials 300, 300′,respectively, according to aspects of the present disclosure. Theexemplary materials 300, 300′ depict embodiments of elasticatedmaterials wherein the bonds within the non-entrapping regions 118 have adifferent spacing than bonds outside of the non-entrapping regions 118,for example within entrapping regions 119. For example, in theembodiment of FIG. 8 , the bonds 20 within the non-entrapping region 118and outside of the non-entrapping region 118 have generally the samesize and shape, however the bonds 20 within the non-entrapping region118 have a longitudinal spacing 305 between longitudinally adjacentbonds 20 that is greater than the longitudinal spacing 25 between bonds20 outside of the non-entrapping region 118. Generally, the longitudinalspacing 305 is greater than the un-tensioned diameter of the elastomericstrands 16 so as to not allow entrapment of the strands 16 within thenon-entrapping region 118. In the embodiment of FIG. 8 , thenon-entrapping region 118 is formed by removing every otherlongitudinally adjacent bond 20 to form the increased longitudinal bondspacing 305. Again, in such embodiments, the average bonded area withinthe non-entrapping region 118 is generally less than the average bondedarea of the regions of the materials 10, 10′ through which the strands16 extend in a generally arcuate manner. The increased longitudinalspacing 305 may help to reduce the number of breakages of theelastomeric strands 16 during formation of the material 300 with respectto the formation of the materials 10 or 10′.

However, other embodiments may accomplish having a reduced averagebonded area within non-entrapping regions while maintaining a similarbond size between bonds within non-entrapping regions and bonds outsideof non-entrapping regions. For example, FIG. 9 depicts exemplarymaterial 300′ which includes non-entrapping region 118 comprising bonds20 which are generally the same size as the bonds 20 outside of thenon-entrapping region 118, for example the entrapping regions 119. Inthe embodiment of material 300′, though, every other laterally adjacentbond of the bonds 20 within the non-entrapping region 118 is missing.Additionally, the first missing bond of the bonds 20 in each rowalternates between longitudinally adjacent rows such that thelongitudinal spacing between longitudinally adjacent bonds 20 within thenon-entrapping region 118 is greater than the longitudinal spacingbetween longitudinally adjacent bonds 20 within the entrapping regions119.

As in the material 300, the longitudinal spacing 305 betweenlongitudinally adjacent bonds 20 within the non-entrapping region 118 inmaterial 300′ may be different than the longitudinal spacing 25 betweenthe longitudinally adjacent bonds 20 in the entrapping regions 119. Ingeneral, the longitudinal spacing 305 is greater than the spacing 25,and more specifically greater than un-tensioned diameter of theelastomeric strands 16 so as to not allow entrapment of the strands 16within the non-entrapping region 118. Like in the embodiment of FIG. 8 ,the elasticated material 300′ in FIG. 9 also has a reduced average bondarea within the non-entrapping region 118 than with respect to theaverage bonded area of the regions of the materials 10, 10′ throughwhich the strands 16 extend in a generally arcuate manner.

Of course, in still further contemplated embodiments, the bonds within anon-entrapping region of an elasticated material may be both smaller insize than bonds outside of the non-entrapping region, as in thematerials 200 and 200′, and may also have relatively larger longitudinalspacing between longitudinally adjacent bonds within the non-entrappingregion, as in the materials 300 and 300′. Additionally, it should beunderstood that the specific shape of the bonds within thenon-entrapping regions and outside of the non-entrapping regions maydiffer as well. FIGS. 10 and 11 depict further exemplary elasticatedmaterials 400 and 400′, respectively, according to these aspects.

Elasticated material 400 of FIG. 10 is similar to elasticated material200′ in that the main difference between the bonds 401 within thenon-entrapping region 118 and the bonds 20 outside of the non-entrappingregion 118 is the bond size. However, in the embodiment of FIG. 10 , theshape of the bonds 401 is also different than the shape of the bonds 20.Although the bonds 401 are shown as generally circular, the bonds 401may be any suitable shape. Elasticated material 400′ of FIG. 11 issimilar to elasticated material 300′ in that the longitudinal spacing oflongitudinally adjacent bonds 401 within the non-entrapping region 118is different than the longitudinal spacing of longitudinally adjacentbonds 20 outside of the non-entrapping region 118. The bonds 401 arealso smaller than the bonds 20. Further, the shape of the bonds 401 inthe embodiment of FIG. 11 within the non-entrapping region 118 is alsodifferent than the shape of the bonds 20 outside of the non-entrappingregion 118. Although the bonds 401 are shown as generally circular, thebonds 401 may be any suitable shape.

FIGS. 12 and 13 depict further exemplary elasticated materials,materials 500, 500′, according to aspects of the present disclosure.Such materials 500, 500′ may be similar to materials 200 and 200′, inthat the elastomeric strands 16 may be entrapped along their arcuateportions 18. However, unlike the materials 200, 200′, the material 500may comprise only the bonds 20 which entrap the strands 16 along thearcuate portions 18 of the strands 16. For example, as can be seen inFIG. 12 , the top strand 16 may extend through un-bonded channels 24 e,24 d, 24 c, and 24 b, as in FIG. 1 . However, in the embodiment of FIG.12 , the bonds 20 which form the portions of the unbonded channels 24 e,24 d, 24 c, and 24 b through which the arcuate portions 18 of the strand16 do not extend have been removed. In some embodiments, the bonds 20which form the portions of the un-bonded channels which arelongitudinally adjacent to the elastomeric strands 16 may be removed.For example, where the top elastomeric strand 16 in FIG. 12 extendsthrough un-bonded channel 24 c, the bonds which form (the longitudinallyadjacent) un-bonded channels 24 b and 24 d have been removed. In thismanner, the un-bonded channels 24 b, 24 d do not exist in the region ofthe material 500 longitudinally adjacent to the top elastomeric strand16 where it extends through un-bonded channel 24 c. In furtherembodiments, the bonds 20 forming the two-closest, longitudinallyadjacent (e.g. two-above and two-below) un-bonded channels to theun-bonded channel through which an arcuate portion 18 of an elastomericstrand 16 extends may be removed. In further embodiments, the bonds 20may be removed which form the closest three (3) to fifty (50)longitudinally adjacent un-bonded channels.

One advantage of such an embodiment is that the average bonded area ofthe material 500 in the region encompassing the arcuate portions 18 ofthe strand 16 is lower than the average bonded area of the material 500outside of the region encompassing the arcuate portions 18 of the strand16. In these embodiments, there may be less of a chance of one or moreof the elastomeric strands 16 becoming broken or otherwise damagedduring manufacture. For example, there may be less of a chance of one ofthe strands 16 aligning with a protrusion on the bonding element 54 ifthe strand 16 did not settle into a region between the protrusions ofthe bonding element 54 which form the bonds 20 which form the desiredun-bonded channels through which the arcuate portions 18 of the strand16 would extend.

In the embodiment of FIG. 13 , the strands 16 of the elasticatedmaterial 500′ are also entrapped along the arcuate portions 18. However,the elasticated material 500′ comprises a differing bond pattern withinthe region of the material 500′ encompassing the arcuate portions 18 ofthe strands 16. For example, instead of removing the bonds 20 which formportions of longitudinally adjacent un-bonded channels, the bonds 20 ofthe material 500′ form a continuous, arcuate un-bonded channel throughwhich the elastomeric strands 16 can extend. In the embodiment of FIG.13 , the top strand 16 can be seen extending through un-bonded channel24 e and then through un-bonded channel 24 d. Laterally adjacent bonds20 within the region of material 500′ encompassing the arcuate portions18 of the strand 16 are shown having a slight longitudinal offset suchthat the un-bonded channel 24 d forms an arcuate path through which thestrand 16 extends. Similarly, the bottom strand 16 in FIG. 13 isdepicted extending through un-bonded channel 24 i and also throughun-bonded channel 24 h, which forms an arcuate path through which thebottom strand 16 extends.

Laterally adjacent bonds 20 which form the arcuate un-bonded channelsmay have longitudinal offsets of anywhere between about 5% to about100%, or between about 5% and about 75%, or between about 5% and about50%. These lateral offset numbers represent a range of distances whichlaterally adjacent bonds 20 may be offset in the longitudinal direction31. That is, instead of laterally adjacent bonds 20 fully overlappingeach other in the lateral direction 32, a bond 20 may be may be shiftedlongitudinally up or down with respect to a laterally adjacent bond 20by the described percentages, wherein the described percentagesrepresent a percentage of a height dimension of the bonds 20 (e.g. suchas height 44 or 209).

Due to the differing bond pattern in the region of the material 500′encompassing the arcuate portions 18 of the strand 16, the average bondarea within this region may be lower than in regions of the material500′ which do not encompass the arcuate portions 18 of the strand 16.Accordingly, similar to elasticated material 500, there may be less of achance of one or more of the elastomeric strands 16 becoming broken orotherwise damaged during manufacture, for example if one or more of thestrands 16 did not align with the regions between the protrusions on oneof the bonding elements while the one or more stands are oscillating.

Of course, although the un-bonded channels through which the arcuateportions 18 of the elastomeric strands 16 extend were shown anddescribed in FIGS. 12 and 13 as entrapping the strands 16, this may notbe the case in all embodiments. In some embodiments of the materials 500and 500′, the bonds 20 may be disposed on opposite sides of the strands16 along the arcuate portions 18 and spaced a distance greater than theun-tensioned diameter of the elastomeric strands 16. Such embodimentsmay be advantageous because the strands 16 may be less likely to bebroken or otherwise damaged during manufacture. For example, it may beeasier for the arcuate portions 18 of the strands 16 to settle betweenthe relatively larger spaces located in-between the protrusions of thebonding element 54 prior to the protrusions forming the bonds 20.

Instead of adjusting the bond pattern to form elasticated materials withentrapping regions 119 and non-entrapping regions 118, adjustments tothe process 100 may be made which will also help to minimize breakage ofthe strands 16 during manufacture. For example, FIGS. 14 and 15 depictalternative exemplary apparatuses for performing processes 100′ and 100″for forming elasticated materials according to the present disclosure.

The process 100′ is similar to the process 100 described with respect toFIG. 5 . However, the process 100′ further comprises a step ofcontacting the bonding element 54 with the one or more elastomericstrands 16 prior to the bonding nip 56. As can be seen in FIG. 14 , theone or more elastomeric strands 16 contact the bonding element 54 atcontact point 51 disposed on the circumference of the bonding element54. As used herein, the term “contact” is not limited to only physicalcontact. Instead, the term “contact” includes states where a firstcomponent is pressed against a second component with one or moreintervening layers preventing direct contact between the first andsecond components. For instance, in the above example, the one or moreelastomeric strands 16 do not directly contact the bonding element 54because the second layer of material is disposed between the one or moreelastomeric strands 16 and the bonding element 54. However, as usedherein, the one or more elastomeric strands 16 are still considered tobe in contact with the bonding element 54.

The one or more elastomeric strands 16 then wrap around the bondingelement 54 for a distance 55 extending between contact point 51 andcontact point 53 on the circumference of the bonding element 54, whichcoincides with the bonding nip 56. Accordingly, distance 55 mayrepresent a circumferential distance. In order to have a low-occurrenceof breakage of the one or more elastomeric strands 16 at the bonding nip56, the distance 55 should be between about 5% and about 75% of theoverall circumference of the bonding element 54. In other embodiments,the distance 55 should be between about 5% and about 50%, or betweenabout 5% and about 45%, or between about 10% and about 40%, or betweenabout 15% and about 35%, or between about 20% and about 30%, of theoverall circumference of the bonding element 54.

By contacting the bonding element 54 along its circumference for thedistance 55 prior to the bonding nip 56, the one or more elastomericstrands 16 are able to settle into regions between the raisedprotrusions of the bonding element 54 prior to reaching the bonding nip56. Accordingly, because the one or more elastomeric strands 16 aredisposed between the raised protrusions once they reach the bonding nip56, the one or more elastomeric strands 16 are not in danger of beingbroken by the protrusions of the bonding element 54 during the bondingof the first layer 12 to the second layer 14.

FIG. 15 is an alternative apparatus for practicing the process 100″. Theapparatus depicted in FIG. 15 is similar to the apparatus depicted inFIG. 12 , including bonding elements 52 and 54. However, the apparatusshown in FIG. 13 further includes guide element 59. Guide element 59 isdisposed adjacent bonding element 54, forming guide nip 58. In thespecific embodiment of FIG. 13 , the guide element 59 is a guide roll.Guide element 59 helps to ensure contact between the second layer 14 andthe one or more elastomeric strands 16 and the bonding element 54 priorto the bonding nip 56. The guide element 59 may be positioned withrespect to the bonding element 54 such that the guide nip 58 is disposedthe circumferential distance 55 away from the bonding nip 56. Inalternative embodiments to that shown in FIG. 15 , the first layer ofmaterial 12 may also be positioned to also extend through the guide nip56 as does the second layer of material 14 and the one or moreelastomeric strands 16.

It should be understood that any of the above embodiments may becombined with any of the other described embodiments in anycombinations. For example, FIG. 11 depicted an exemplary elasticatedmaterial 400′ which combined the features of materials 200′ and 300′where the bonds 401 within non-entrapping region 118 have both adifferent (greater) longitudinal spacing between longitudinally adjacentbonds 401 than the longitudinal spacing between longitudinally adjacentbonds within entrapping regions 119, along with the bonds 401 having asmaller size than the bonds 20. The elasticated material 400′ could bemade according to any of the described processes 100, 100′, or 100″. Insome embodiments of the present disclosure, contemplated elasticatedmaterials may have any bond pattern described herein, or any othersuitable bond pattern, and be made according to any one of the processes100, 100′, or 100″. Although the bond patterns comprising non-entrappingregions 118 were described as useful for making elasticated materialshaving elastomeric strands with arcuate portions easier to manufacture,nothing in this disclosure should be construed as preventing such bondpatterns being formed according to the process 100′ or 100″, both ofwhich are also described as helping to make the manufacture elasticatedmaterials having elastomeric strands with arcuate portions easier.

Of course, any of the above described elasticated materials may be usedwithin various different clothing garments and absorbent articles. Forinstance, the disclosed elasticated materials may form at least aportion of a waistband or waist panel of a clothing garment or absorbentarticle, or at least a portion of elastomeric leg cuffs of a clothinggarment or absorbent article. The disclosed materials may be used withinother portions of absorbent articles such as within an absorbent core ofan absorbent article, as part of a containment flap of an absorbentarticle, or as part of a surge and/or distribution layer of an absorbentarticle.

FIG. 16 depicts exemplary absorbent article 500 which includeselasticated materials as part of its waistbands, leg cuffs, andcontainment flaps. The embodiment of FIG. 16 illustrates absorbentarticle 500 which comprises an absorbent article manufactured in what iscommonly termed a cross-machine direction (CD) process. However, itshould be understood that other absorbent articles which aremanufactured in machine-direction (MD) processes may contain elasticatedmaterials according to the present disclosure without departing from thespirit and scope of the disclosure.

The absorbent article 500 can comprise a three-piece construction wherethe absorbent article 500 has a chassis 506 including a front waistpanel 502 having a front waist edge 501, a rear waist panel 504 having arear waist edge 503, and an absorbent panel 509 extending between thefront waist panel 502 and the rear waist panel 504. The absorbent panel509 may generally include absorbent body 508.

In some embodiments, the absorbent panel 509 can have a first lateralside edge 505 and a second lateral side edge 507 and can overlap thefront waist panel 502 and the rear waist panel 504. The absorbent panel509 can be bonded to the front waist panel 502 and the rear waist panel504 to define a three-piece construction. However, it is contemplatedthat an absorbent article can be manufactured in a CD process withoutbeing a three-piece construction garment, which is also sometimesreferred to as a one-piece construction (not shown), as the front waistpanel 502 and the rear waist panel 504 are integral with one another byway of commonly connected components forming the waist panel such as abodyside liner and/or an outer cover which can envelope the absorbentpanel 509 or simply cover the garment side of the absorbent panel 509.

The front waist panel 502 and the rear waist panel 504 may generallycomprise elastomeric strands 516 disposed between at least two layers ofmaterial. For instance, the front waist panel 502 and the rear waistpanel 504 may comprise an elasticated material such as those asdescribed herein. These different embodiments may impart differentbeneficial fit properties to the absorbent article 500. For example, oneor more of the strands 516 may extend throughout at least a portion ofthe front and/or rear waist panels 502, 504 in an arcuate manner, suchas strands 516 a-d. These arcuate strands 516, or portions of thestrands 516, may allow for a closer and/or more comfortable fit of thearticle 500 when worn, such as by providing better contouring of thearticle 500 on a body.

Similarly, leg cuffs 510, 511 may be formed with one or more elastomericstrands 517. In some embodiments, portions 518 of one or more of thestrands 517 may extend in an arcuate manner, according to any of theembodiments described herein. This may allow for a better fit of thearticle 500 where the leg cuffs 510, 511 are better able to conform to awearer's body, such as around the legs. In some additional oralternative embodiments, containment flaps 512 may also comprise one ormore elastomeric strands 521. At least some portions, such as portions522, of these elastomeric strands 521 may extend in an arcuate manner,according to any of the embodiments described herein, so as to betterconform to a wearer's body to help preventing leaking.

FIG. 17 depicts another exemplary absorbent article 600 which maybenefit from using one or more of the materials disclosed herein. Thearticle 600 includes chassis 602 and body facing surface 603 and mayfurther include front side panels 609 and rear side panels 608. Thefront side panels 609 may include attachment region 607, while the rearside panels 608 may include attachment region 609. The attachmentregions 607, 609 may cooperate with one another to from a secureconnection between the front side panels 609 and the rear side panels609. In such a configuration, the article 600 may be considered to be ina wear configuration.

In some embodiments, it may be beneficial for at least one of the frontside panels 609 and/or the rear side panels 608 to comprise one or moreelastomeric strands that have one or more arcuate portions (not shown).Accordingly, front side panels 609 and/or the rear side panels 608 maycomprise any of the materials described herein. The front side panels609 and/or the rear side panels 608 may benefit from implementation ofelastomeric strands having arcuate portions to in order to provide abetter fit for article 600. Since the front side panels 609 and/or therear side panels 608 sit extend around a portion of a waist and legs ofa wearer, the arcuate portions of elastomeric strands of the front sidepanels 609 and/or the rear side panels 608 may provide for bettercontouring of the article 600 resulting in a better fit.

Article 600 may further comprise leg cuffs 610, which may be formed withone or more elastomeric strands 611. In some embodiments, portions ofone or more of the strands 611 may extend in an arcuate manner, such asportions 612, according to any of the embodiments described herein. Thismay allow for a better fit of the article 600 where the leg cuffs 610are better able to conform to a wearer's body, such as around the legs.In some additional or alternative embodiments, containment flaps 615 mayalso comprise one or more elastomeric strands 616. At least someportions of these elastomeric strands 616, such as portions 618, mayextend in an arcuate manner according to any of the embodimentsdescribed herein. These arcuate portions 618 may allow the containmentflaps 615 to better conform to a wearer's body to help preventingleaking. In still further additional or alternative embodiments, thearticle 600 may comprise a front waistband 620 and/or a rear waistband621. In various embodiments, the front waistband 620 and/or a rearwaistband 621 way comprise one or more elastomeric strands which extendin an arcuate manner, according to any of the materials disclosedherein. Such arcuate portions in the front waistband 620 and/or a rearwaistband 621 may help provide the article 600 with a better fitcharacteristic.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

Those skilled in the art will recognize that the present disclosure maybe manifested in a variety of forms other than the specific embodimentsdescribed and contemplated herein. Specifically, the various featuresdescribed with respect to the various embodiments and figures should notbe construed to be applicable to only those embodiments and/or figures.Rather, each described feature may be combined with any other feature invarious contemplated embodiments, either with or without any of theother features described in conjunction with those features.Accordingly, departure in form and detail may be made without departingfrom the scope of the present disclosure as described in the appendedclaims.

EMBODIMENTS

In a first embodiment, a method for forming an elasticated material maycomprise advancing a first continuous substrate material having an uppersurface and a lower surface in a machine direction, advancing a secondcontinuous substrate material having an upper surface and a lowersurface in the machine direction, and advancing an elastomeric strand ina stretched state in the machine direction, wherein the elastomericstrand is positioned between the lower surface of the first continuoussubstrate material and the upper surface of the second continuoussubstrate material. The method may further comprise advancing the firstcontinuous substrate material and the second continuous substratematerial with the elastomeric strand positioned therebetween to abonding apparatus. The bonding apparatus may comprise a first bondingelement and a second bonding element disposed proximate the firstbonding element and forming a bonding nip with the first bondingelement. The method may also comprise oscillating the elastomeric strandin a cross-machine direction, advancing the first continuous substratematerial, the second continuous substrate material, and the elastomericstrand through the bonding nip and bonding the first continuoussubstrate material to the second continuous substrate material with theelastomeric strand disposed therebetween with at least a first bond anda second bond. The first bond and the second bond may be disposed onopposite sides of the elastomeric strand and spaced apart a distanceless than an un-tensioned diameter of the elastomeric strand and may belocated along a portion of the elastomeric strand which extends in anarcuate manner.

In a second embodiment, the second bonding element of the firstembodiment may have an outer edge comprising a circumference, and thesecond continuous substrate and the elastomeric strand may contact thesecond bonding element along the outer edge for a contact length that isbetween about 5% and about 75% of the circumference.

In a third embodiment, the second bonding element of any of the firstand second embodiments may be a roll having an outer edge comprising acircumference, and the second continuous substrate and the elastomericstrand may contact the second bonding element along the outer edge for acontact length that is between about 15% and about 50% of thecircumference.

In a fourth embodiment, the first continuous substrate material of thesecond embodiment may contact the second bonding element along the outeredge for a contact length that is between about 5% and about 75% of thecircumference.

In a fifth embodiment, the step of bonding the first continuoussubstrate material to the second continuous substrate material with theelastomeric strand disposed therebetween of any of the first throughfourth embodiments may further comprise forming a third bond and afourth bond disposed on opposite sides of the elastomeric strand. Thethird bond and the fourth bond may be spaced apart a distance less thanan un-tensioned diameter of the elastomeric strand and located along aportion of the elastomeric strand which extends in a straight manner.

In a sixth embodiment, the method of any of the first through fifthembodiments may not include a step of applying adhesive between thefirst continuous substrate material and the second continuous substratematerial.

In a seventh embodiment, the first bond and the second bond of any ofthe first through sixth embodiments may be formed by pressure bonding.

In an eighth embodiment, the first bond and the second bond of any ofthe first through sixth embodiments may be formed by ultrasonic bonding.

In a ninth embodiment, a method for forming an elasticated material maycomprise advancing a first continuous substrate material having an uppersurface and a lower surface in a machine direction, advancing a secondcontinuous substrate material having an upper surface and a lowersurface in the machine direction, advancing an elastomeric strand in astretched state in the machine direction, wherein the elastomeric strandis positioned between the lower surface of the first continuoussubstrate material and the upper surface of the second continuoussubstrate material, and advancing the first continuous substratematerial and the second continuous substrate material with theelastomeric strand positioned therebetween to a bonding apparatus. Thebonding apparatus may comprise a first bonding element, a second bondingelement disposed proximate the first bonding element and forming abonding nip with the first bonding element, and a guide element disposedproximate the second bonding element and forming a guide nip with thesecond bonding element. The method may further comprise oscillating theelastomeric strand in a cross-machine direction, advancing the secondcontinuous substrate and the elastomeric strand through the guide nip sothat the second continuous substrate and the elastomeric contact thesecond bonding element prior to the bonding nip, and advancing the firstcontinuous substrate material, the second continuous substrate material,and the elastomeric strand through the bonding nip and bonding the firstcontinuous substrate material to the second continuous substratematerial with the elastomeric strand disposed therebetween with at leasta first bond and a second bond. The first bond and the second bond maybe disposed on opposite sides of the elastomeric strand and spaced aparta distance less than an un-tensioned diameter of the elastomeric strandand located along a portion of the elastomeric strand which extends inan arcuate manner.

In a tenth embodiment, the second bonding element of the ninthembodiment may be a roll having an outer edge comprising acircumference, and the guide nip may be disposed such that a distancebetween the bonding nip and the guide nip, along the outer edge of thesecond bonding element, is between about 5% and about 75% of thecircumference.

In an eleventh embodiment, the second bonding element of any of theninth and tenth embodiments may be a roll having an outer edgecomprising a circumference, and the guide nip may be disposed such thata distance between the bonding nip and the guide nip, along the outeredge of the second bonding element, is between about 15% and about 50%of the circumference.

In a twelfth embodiment, the method of any of the ninth through eleventhembodiments may further comprise advancing the first continuoussubstrate material through the guide nip along with the secondcontinuous substrate material and the first continuous substratematerial.

In a thirteenth embodiment, the step of bonding the first continuoussubstrate material to the second continuous substrate material with theelastomeric strand disposed therebetween of any of the ninth throughtwelfth embodiments may further comprise forming a third bond and afourth bond disposed on opposite sides of the elastomeric strand. Thethird bond and the fourth bond may be spaced apart a distance less thanan un-tensioned diameter of the elastomeric strand and located along aportion of the elastomeric strand which extends in a straight manner.

In a fourteenth embodiment, the method of any of the ninth throughthirteenth embodiments may not include a step of applying adhesivebetween the first continuous substrate material and the secondcontinuous substrate material.

In a fifteenth embodiment, the first bonding element and the secondbonding element of any of the ninth through fourteenth embodiments maycomprise rolls.

In a sixteenth embodiment, an elasticated material may comprise a firstsubstrate layer, a second substrate layer, an elastomeric stranddisposed between the first substrate layer and the second substratelayer, and a plurality of bonds bonding the first substrate layer to thesecond substrate layer. The elastomeric strand may comprise at least onestraight portion and at least one arcuate portion. The plurality ofbonds may comprise a first bond and a second bond, and the first bondand the second bond may be disposed on opposite sides of the elastomericstrand and spaced apart a distance less than an un-tensioned diameter ofthe elastomeric strand and located along an arcuate portion of theelastomeric strand.

In a seventeenth embodiment, the plurality of bonds further of thesixteenth embodiment may further comprise a third bond and a fourthbond, and the third bond and the second bond may be disposed on oppositesides of the elastomeric strand. The third bond and the fourth bond maybe spaced apart a distance less than an un-tensioned diameter of theelastomeric strand located along the at least one straight portion ofthe elastomeric strand.

In an eighteenth embodiment, the material of any of the sixteenth andseventeenth embodiments may not include adhesive.

In a nineteenth embodiment, the plurality of bonds of any of thesixteenth through eighteenth embodiments may be disposed in bond rowsforming a plurality of un-bonded channels extending betweenlongitudinally adjacent bond rows, and the arcuate portion of theelastomeric strand may extend between multiple of the plurality ofun-bonded channels.

In a twentieth embodiment, the plurality of bonds of any of thesixteenth through nineteenth embodiments may be disposed in bond rowsforming a plurality of un-bonded channels extending betweenlongitudinally adjacent bond rows and a portion of the plurality ofbonds form may an un-bonded channel having an arcuate shape.Additionally, the arcuate portion of the elastomeric strand may extendthrough the arcuate un-bonded channel.

In a twenty-first embodiment, an elasticated material may extend in alateral direction and a longitudinal direction and may comprise a firstweb of material and a second web of material bonded to the first web ofmaterial by a plurality of bonds. The plurality of bonds may comprise afirst series of opposing bond pairs extending in the lateral direction,the first series of opposing bond pairs defining a first un-bondedchannel extending between the first series of opposing bond pairs, and asecond series of opposing bond pairs extending in the lateral directionand spaced longitudinally from the first series of opposing bond pairs,the second series of opposing bond pairs defining a second un-bondedchannel extending between the second series of opposing bond pairs. Thematerial may further comprise an elastomeric strand extending in thelateral direction and disposed between the first web of material and thesecond web of material. A first portion of the elastomeric strand may bedisposed within the first un-bonded channel, and a second portion of theelastomeric strand may be disposed within the second un-bonded channel.

In a twenty-second embodiment, the bonds of at least one bond pair ofthe first series of opposing bond pairs, of the material of thetwenty-first embodiment, which define a portion of the first un-bondedchannel in which the elastomeric strand is situated may be spaced apartin the longitudinal direction a distance less than an un-tensioneddiameter of the elastomeric strand.

In a twenty-third embodiment, the bonds of at least one bond pair of thefirst series of opposing bond pairs, of the material of thetwenty-second embodiment, may be spaced apart in the longitudinaldirection a distance greater than the un-tensioned diameter of theelastomeric strand.

In a twenty-fourth embodiment, the bonds which are spaced apart in thelongitudinal direction a distance less than the un-tensioned diameter ofthe elastomeric strand, of the material of the twenty-third embodiment,may have first bond areas, the bonds which are spaced apart in thelongitudinal direction a distance greater than the un-tensioned diameterof the elastomeric strand, of the material of the twenty-thirdembodiment, may have second bond areas, and the second areas may besmaller than the first areas.

In a twenty-fifth embodiment, the bonds which are spaced apart in thelongitudinal direction a distance less than the un-tensioned diameter ofthe elastomeric strand, of the material of the twenty-third embodiment,may be polygons, and the bonds which are spaced apart in thelongitudinal direction a distance greater than the un-tensioned diameterof the elastomeric strand, of the material of the twenty-thirdembodiment, may be round.

In a twenty-seventh embodiment, the bonds of at least one bond pair ofthe second series of opposing bond pairs which define a portion of thesecond un-bonded channel, of the material of any of the twenty-secondthrough twenty-sixth embodiments, may be spaced apart in thelongitudinal direction a distance less than an un-tensioned diameter ofthe elastomeric strand.

In a twenty-seventh embodiment, the bonds of at least one bond pair ofthe second series of opposing bond pairs which define a portion of thesecond un-bonded channel, of the material of any of the twenty-secondthrough twenty-sixth embodiments, may be spaced apart in thelongitudinal direction a distance greater than the un-tensioned diameterof the elastomeric strand.

In a twenty-eighth embodiment, the second portion of the elastomericstrand of the material of the twenty-seventh embodiment, which isdisposed within the second un-bonded channel, may not pass between anybond pairs of the second series of opposing bond pairs which are spacedapart in the longitudinal direction a distance less than theun-tensioned diameter of the elastomeric strand.

In a twenty-ninth embodiment, the first series of opposing bond pairs,of the material of any of the twenty-first through twenty-eighthembodiments, may not be adjacent to the second series of opposing bondpairs.

In a thirtieth embodiment, the material of any of the twenty-firstthrough twenty-ninth embodiments may further comprise a third series ofopposing bond pairs extending in the lateral direction and spacedlongitudinally from the first series of opposing bond pairs and thesecond series of opposing bond pairs, the third series of opposing bondpairs defining a third un-bonded channel extending between the thirdseries of opposing bond pairs, and a third portion of the of theelastomeric strand may be disposed within the third un-bonded channel.

In a thirty-first embodiment, a third portion of the elastomeric strandof any of the twenty-first through thirtieth embodiments may be disposedwithin the first un-bonded channel, the second portion being disposedbetween the first portion and the third portion.

In a thirty-second embodiment, an elasticated material extending in alateral direction and a longitudinal direction may comprise a first webof material, a second web of material bonded to the first web ofmaterial by a plurality of bonds, at least some of the plurality ofbonds forming bond pairs, and an elastomeric strand extending in thelateral direction and disposed between the first web of material and thesecond web of material. The elastomeric strand may form an arcuateshape, and the elastomeric strand may extend between a plurality of thebond pairs, at least some of the plurality of the bond pairs havingbonds which are separated by a longitudinal distance that is less thanan un-tensioned diameter of the elastomeric strand.

In a thirty-third embodiment, at least some of the plurality of bondpairs of the thirty-second embodiment through which the elastomericstrand extends may have bonds which are separated by a longitudinaldistance that is greater than an un-tensioned diameter of theelastomeric strand.

In a thirty-fourth embodiment, the bonds of the thirty-third embodimentwhich are separated by a longitudinal distance that is less than anun-tensioned diameter of the elastomeric strand may have first bondareas, and the bonds which are spaced apart in the longitudinaldirection a distance greater than the un-tensioned diameter of theelastomeric strand may have second bond areas which are less than thefirst bond areas.

In a thirty-fifth embodiment, the bonds of any of the thirty-third andthirty-fourth embodiments which are spaced apart in the longitudinaldirection a distance less than the un-tensioned diameter of theelastomeric strand may be polygons, and the bonds which are spaced apartin the longitudinal direction a distance greater than the un-tensioneddiameter of the elastomeric strand may be round.

In a thirty-sixth embodiment, the elastomeric strand of any of thethirty-third through thirty-fifth embodiments may extend through thebonds which are spaced apart in the longitudinal direction a distanceless than the un-tensioned diameter of the elastomeric strand in astraight path, and the elastomeric strand may extend through the bondswhich are spaced apart in the longitudinal direction a distance greaterthan the un-tensioned diameter of the elastomeric strand in an arcuatepath.

What is claimed is:
 1. A method for forming an elasticated material, themethod comprising: advancing a first continuous substrate materialhaving an upper surface and a lower surface in a machine direction;advancing a second continuous substrate material having an upper surfaceand a lower surface in the machine direction; advancing an elastomericstrand in a stretched state in the machine direction, wherein theelastomeric strand is positioned between the lower surface of the firstcontinuous substrate material and the upper surface of the secondcontinuous substrate material; advancing the first continuous substratematerial and the second continuous substrate material with theelastomeric strand positioned therebetween to a bonding apparatus,wherein the bonding apparatus comprises: a first bonding element, and asecond bonding element disposed proximate the first bonding element andforming a bonding nip with the first bonding element; oscillating theelastomeric strand in a cross-machine direction; and advancing the firstcontinuous substrate material, the second continuous substrate material,and the elastomeric strand through the bonding nip and bonding the firstcontinuous substrate material to the second continuous substratematerial with the elastomeric strand disposed therebetween with at leasta first bond and a second bond, wherein the first bond and the secondbond are disposed on opposite sides of the elastomeric strand and spacedapart a distance less than an un-tensioned diameter of the elastomericstrand, and wherein the first bond and the second bond are located alonga portion of the elastomeric strand which extends in an arcuate manner.2. The method of claim 1, wherein the second bonding element is a rollhaving an outer edge comprising a circumference, and wherein the secondcontinuous substrate and the elastomeric strand contact the secondbonding element along the outer edge for a contact length that isbetween about 5% and about 75% of the circumference.
 3. The method ofclaim 1, wherein the second bonding element is a roll having an outeredge comprising a circumference, and wherein the second continuoussubstrate and the elastomeric strand contact the second bonding elementalong the outer edge for a contact length that is between about 15% andabout 50% of the circumference.
 4. The method of claim 2, wherein thefirst continuous substrate material contacts the second bonding elementalong the outer edge for a contact length that is between about 5% andabout 75% of the circumference.
 5. The method of claim 1, whereinbonding the first continuous substrate material to the second continuoussubstrate material with the elastomeric strand disposed therebetweenfurther comprises: forming a third bond and a fourth bond disposed onopposite sides of the elastomeric strand, wherein the third bond and thefourth bond are spaced apart a distance less than an un-tensioneddiameter of the elastomeric strand, and wherein the third bond and thefourth bond are located along a portion of the elastomeric strand whichextends in a straight manner.
 6. The method of claim 1, wherein themethod does not include a step of applying adhesive between the firstcontinuous substrate material and the second continuous substratematerial.
 7. The method of claim 1, wherein the first bond and thesecond bond are formed by pressure bonding.
 8. The method of claim 1,wherein the first bond and the second bond are formed by ultrasonicbonding.
 9. A method for forming an elasticated material, the methodcomprising: advancing a first continuous substrate material having anupper surface and a lower surface in a machine direction; advancing asecond continuous substrate material having an upper surface and a lowersurface in the machine direction; advancing an elastomeric strand in astretched state in the machine direction, wherein the elastomeric strandis positioned between the lower surface of the first continuoussubstrate material and the upper surface of the second continuoussubstrate material; advancing the first continuous substrate materialand the second continuous substrate material with the elastomeric strandpositioned therebetween to a bonding apparatus, wherein the bondingapparatus comprises: a first bonding element, a second bonding elementdisposed proximate the first bonding element and forming a bonding nipwith the first bonding element, and a guide element disposed proximatethe second bonding element and forming a guide nip with the secondbonding element; oscillating the elastomeric strand in a cross-machinedirection; advancing the second continuous substrate and the elastomericstrand through the guide nip so that the second continuous substrate andthe elastomeric contact the second bonding element prior to the bondingnip; and advancing the first continuous substrate material, the secondcontinuous substrate material, and the elastomeric strand through thebonding nip and bonding the first continuous substrate material to thesecond continuous substrate material with the elastomeric stranddisposed therebetween with at least a first bond and a second bond,wherein the first bond and the second bond are disposed on oppositesides of the elastomeric strand and spaced apart a distance less than anun-tensioned diameter of the elastomeric strand, and wherein the firstbond and the second bond are located along a portion of the elastomericstrand which extends in an arcuate manner.
 10. The method of claim 9,wherein the second bonding element is a roll having an outer edgecomprising a circumference, and wherein the guide nip is disposed suchthat a distance between the bonding nip and the guide nip, along theouter edge of the second bonding element, is between about 5% and about75% of the circumference.
 11. The method of claim 9, wherein the secondbonding element is a roll having an outer edge comprising acircumference, and wherein the guide nip is disposed such that adistance between the bonding nip and the guide nip, along the outer edgeof the second bonding element, is between about 15% and about 50% of thecircumference.
 12. The method of claim 9, further comprising advancingthe first continuous substrate material through the guide nip along withthe second continuous substrate material and the first continuoussubstrate material.
 13. The method of claim 9, wherein bonding the firstcontinuous substrate material to the second continuous substratematerial with the elastomeric strand disposed therebetween furthercomprises: forming a third bond and a fourth bond disposed on oppositesides of the elastomeric strand, wherein the third bond and the fourthbond are spaced apart a distance less than an un-tensioned diameter ofthe elastomeric strand, and wherein the third bond and the fourth bondare located along a portion of the elastomeric strand which extends in astraight manner.
 14. The method of claim 9, wherein method does notinclude a step of applying adhesive between the first continuoussubstrate material and the second continuous substrate material.
 15. Themethod of claim 9, wherein at least one of the first bonding element andthe second bonding element comprise rolls.
 16. An elasticated materialcomprising: a first substrate layer; a second substrate layer; anelastomeric strand disposed between the first substrate layer and thesecond substrate layer; and a plurality of bonds bonding the firstsubstrate layer to the second substrate layer, wherein the elastomericstrand comprises at least one straight portion and at least one arcuateportion, wherein the plurality of bonds comprises a first bond and asecond bond, and the first bond and the second bond are disposed onopposite sides of the elastomeric strand and spaced apart a distanceless than an un-tensioned diameter of the elastomeric strand, andwherein the first bond and the second bond are located along an arcuateportion of the elastomeric strand.
 17. The elasticated material of claim16, wherein: the plurality of bonds further comprises a third bond and afourth bond, and the third bond and the second bond are disposed onopposite sides of the elastomeric strand, wherein the third bond and thefourth bond are spaced apart a distance less than an un-tensioneddiameter of the elastomeric strand, and wherein the third bond and thefourth bond are located along the at least one straight portion of theelastomeric strand.
 18. The elasticated material of claim 16, whereinthe material does not include adhesive.
 19. The elasticated material ofclaim 16, wherein the plurality of bonds are disposed in bond rowsforming a plurality of un-bonded channels extending betweenlongitudinally adjacent bond rows, and wherein the arcuate portion ofthe elastomeric strand extends between multiple of the plurality ofun-bonded channels.
 20. The elasticated material of claim 16, whereinthe plurality of bonds are disposed in bond rows forming a plurality ofun-bonded channels extending between longitudinally adjacent bond rows,and wherein a portion of the plurality of bonds form an un-bondedchannel having an arcuate shape, and wherein the arcuate portion of theelastomeric strand extends through the arcuate un-bonded channel.